OMS Series 2 and Series 3 Orbital Motors Service and Parts Manual

OMS Series 2
and Series 3
Orbital Motors
Service and Parts

Manual
OMS/OMSW Orbital Motor
Service and Parts Manual
Table of Contens, Special Versions
Revision History Table of Revisions

Date Page Changed Rev
Jun 2006 All First edition AA
May 2009 AB
May 2010 16 Japan location AC
Sep 2010 16 New back cover AD
Contents Special versions....................................................................................................................................................................3

Cost-free repairs...................................................................................................................................................................3
Comments ............................................................................................................................................................................3
OMS series 2..........................................................................................................................................................................3
OMS series 3 with brake nose.........................................................................................................................................3
Exploded view OMS series 2 ..........................................................................................................................................4
Exploded view OMS series 3 ..........................................................................................................................................5
Spare parts list......................................................................................................................................................................7
Special tools....................................................................................................................................................................... 10
Dismantling........................................................................................................................................................................ 11
Tacho connection............................................................................................................................................................. 12
Assembling......................................................................................................................................................................... 13
© 2010 Sauer-Danfoss. All rights reserved.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already
ordered provided that such alterations can be made without affecting agreed specifications. All trademarks
in this material are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype, the
Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in Motion™ are trademarks of the
Sauer-Danfoss Group.
Frontpage: P300 083, Drawing 151-19
2 11007891 • Rev AD • Sep 2010

Contents
Special Versions The list of spare parts cannot be used when ordering parts for special OMS versions.
In this respect, please contact the sales organisation for Sauer-Danfoss.
Cost-Free Repairs We would point out that cost-free repairs as mentioned in Sauer-Danfoss General
Conditions of Sale, are carried out only at Sauer-Danfoss Nordborg or at service shops
authorised by Sauer-Danfoss.
Comments a) Only OMS series 2:

After week 41.97 the guide pin has a new location. When repairing motors
manufacturing before week 41.97 it will therefore be necessary to replace end cover,
balance plate, tightening pin and spring washer.
Series Marking The series number is altering when parts in the motor are changed.
The OMS series marking follows its date marking: XXX-3
OMS Series 3
OMSW Series 3 with

Brake Nose
11007891 • Rev AD • Sep 2010 3

Exploded View OMS Series 2
Exploded View OMS

Series 2
Tightening torque: t
Item 13, with item 14: 30 - 60 N.m [ 270 - 530 lbf.in]

Item 34: 75 - 80 N.m [660 - 705 lbf.in]
Item 38: 10 - 15 N.m [90 - 130 lbf.in]
Item 51: 4 - 6 N.m [35 - 55 lbf.in]

4 11007891 • Rev AD • Sep 2010

Exploded View OMS

Series 3
Item 13, with item 14: 30 - 60 N.m [ 270 - 530 lbf.in]

11007891 • Rev AD • Sep 2010 5

Exploded View OMS

Series 3
151-2090.11
Item 34: 75 - 80 N.m [660 - 705 lbf.in]

Item 51: 4 - 6 N.m [35 - 55 lbf.in]

6 11007891 • Rev AD • Sep 2010

Spare Parts List
Spare Parts List Item Spare parts Number per motor

Code No. Series
2 3
1 Dust seal ring 35 • 42 • 3.5 mm [1.38 • 1.65 • 0.14 in] 633B3198 1 1
(p.t.o. shaft) 40 • 47 • 4.0 mm [1.57 • 1.85 • 0.16 in] 633B3356 1 1
2 Bearing housing
OMS Standard flange 151F1534 1 1
OMS Standard flange and P.t.o. shaft 151F1549 1 1
OMS Special flange 151F1536 1 1
OMS A - 2 flange 151F1685 1 1
OMS Magneto flange 151F1858 1 1
OMS SAE B flange 151F1864 1 1
OMSW Metric standard 151F1535 1 1
OMSW SAE standard 151F1572 1 1
OMSW with brake nose 151F1852 1
2a Mounting flange 151F1827 1
3 Shaft seal 35 • 52 • 5 mm [1.38 • 2,05 • 0.20 in] NBR 633B3197 1 1
35 • 52 • 5 mm [1.38 • 2,05 • 0.20 in] FPM 633B3196 1 1
P.t.o. shaft 40 • 60 • 6 mm [1.57 • 2.36 • 0.24 in] NBR 633B3355 1 1
4 Parallel key Metric: A 10 • 8 • 45 mm for 32 mm cyl. shaft 682L8019 1 1
Metric: B 6 • 6 • 20 mm for tap. shaft 682L8021 1 1
SAE: 5/16 • 5/16 • 1 ¼ in for 1 ¼ in cyl. 151-4109 1 1
and tapered shaft
SAE: ¼ • ¼ • 1 ¼ in BS 46 for 1 in cylindrical shaft 682L8036 1 1
5 Cylindrical shaft Metric: Ø32 mm with bearings incl. item 4 151F0112 1 1
SAE: Ø1 ¼ in with bearings incl. item 4 151F0118 1 1
SAE: Ø1 in with bearings incl. item 4 151F0127 1 1
6 Splined shaft Metric: 1 ¼ in with bearings 151F0113 1 1
SAE: 1 ¼ in with bearings 151F0119 1 1
SAE: 1 in with bearings 151F0126 1 1
SAE: 0.875 in with bearings 151F0138 1 1
7 P.t.o. shaft incl. bearing, DIN 9611 151F0116 1 1
8 Washer metric version only 20.5 • 44 • 4 mm 684X2530 1 1
9 Castellated nut Metric: M20 • 1.5 mm 681X8235 1 1
SAE: 1 - 20 UNEF 151-4154 1 1
10 Tapered shaft Metric: 35 mm with bearings incl. item 4, (8) and 9 151F0114 1 1
SAE: 1 ¼ in with bearings incl. item 4 and 9 151F0115 1 1
11 Conical seal ring 633B9023 1 1
12 O-ring 70 • 2 mm [2.75 • 0.08] NBR 633B1379 1 1
13 Drain plug Metric: G¼ 151-1524 1 1
SAE: 7/16 - 20 UNF 151-5439 1 1
14 Washer 684X2120 1 1
15 Intermediate plate Metric: 151F1811 1
Metric: 151F1538 1
SAE: 151F1812 1
SAE: 151F1553 1
16 Mounting flange for OMSS
Metric: 151F1817 1
Metric: 151F1486 1
SAE: 151F1570 1
11007891 • Rev AD • Sep 2010 7

Spare Parts List
Spare Parts List Item Spare parts Number per motor

Code No. Series
2 3
17 O-ring for OMSS 100 • 3 mm [3.94 • 0.12 in] NBR 633B1486 1 1
18 Cardan shaft
OMS/OMSW/OMSS 80 l = 70 mm [2.75 in] 151F1461 1 1
OMS/OMSW/OMSS 250 l = 99.5 mm [3.92 in] 151F1770 1 1
19 O-ring 82.5 • 2 mm [3.25 • 0.08 in] NBR 633B1431 2 3
20 Gearwheel set Series 3
OMS/OMSW/OMSS 80 w = 14 mm [0.55 in] 151F1081 1
OMS/OMSW/OMSS 315 w = 55 mm [2.16in] 151F1087 1
OMS/OMSW/OMSS 400 w = 68.4 mm [2.69 in] 151F1088 1
20 Gearwheel set Series 2
OMS/OMSW/OMSS 315 w = 55 mm [2.16in] 151F1042 1
21 Guide pin Ø 4 mm [0.16 in], l = 10 mm [0.39 in] DIN 6325 682L2006 1
22 Valve drive OMS 80 - 400 151F1448 1 1
OMS 500 151F1862 1 1
23 Channel plate 151F1821 1
151F1023 1
24 Stop ring (OMSS 200, 250, 315, 400 and 500 only) 151F1542 1 1
25 Disc valve 151F1022 1 1
26 Balance plate a) 151F1738 1 1
27 Guide pin Ø 5 mm [0.20 in], l = 14 mm [0.55 in] ISO 8752 a) 682L9105 1 1
28 O-ring 45 • 2 mm [1.77 • 0.08] NBR 633B1429 1 1
45 • 2 mm [1.77 • 0.08] FPM 633B1455 1 1
29 O-ring 24 • 2 mm [0.94 • 0.08] NBR 633B1428 1 1
24 • 2 mm [0.94 • 0.08] FPM 633B1453 1 1
30 Spacer 151F1449 1 1
31 Spring washer a) 684X0097 1 1
32 Valve housing sideport Metric: a) 151F1445 1
a) see comments page 3 32a Metric: 151F1801 1
8 11007891 • Rev AD • Sep 2010

Spare Parts List
Item Spare parts Number per motor

Code No. Series
2 3
32 Valve housing sideport SAE: a) 151F1552 1
32a without drain port SAE 151F1805 1
32b with drain port SAE 151F1807 1
32c endport without drain port SAE 151F1855 1
32d with drain port SAE 151F1856 1
33 Seal plug 633X0017 2 2
34 Screw M10:
OMS/OMSW 80 l = 120 mm [4.72 in] 681X1349 4 4
OMS/OMSW 100, 125 l = 130 mm [5.12 in] 681X1350 4 4
OMS/OMSW 160, 200 l = 140 mm [5.51 in] 681X1352 4 4
OMS/OMSW 250 l = 150 mm [5.91 in] 681X1353 4 4
OMS/OMSW 315 l = 160 mm [6.30 in] 681X1356 4 4
OMS/OMSW 400, 500 l = 180 mm [7.09 in] 681X0038 4 4
OMSS 80, 100 l = 100 mm [3.94 in] 681X1347 4 4
OMSS 125, 160 l = 110 mm [4.33 in] 681X1348 4 4
OMSS 200 l = 120 mm [4.72 in] 681X1349 4 4
OMSS 250 l = 130 mm [5.12 in] 681X1350 4 4
OMSS 315 l = 140 mm [5.52 in] 681X1352 4 4
OMSS 400, 500 l = 150 mm [5.91 in] 681X1353 4 4
35 Check valve ball ** Ø3/16 in 689X1005 2
Ø¼ in 689X1015 2
36 Check valve spring 013-0662 2
37 Washer 10.2 • 13.5 • 7 mm [0.40 • 0.53 • 0.27 in] 684X2564 2
38 Check valve plug G 1/8 631X2053 2
39 Name plate: Aluminium OMS, OMSW, OMSS 151A0407 1 1
Brass OMS, OMSW, OMSS 151A0408 1 1
43 Tacho valve housing, complete 151F0137 1
a) 151F0100 1
44 Tacho connection, complete 151F1031 1 1
45 Tacho valve drive + guide pin 151F1032 1 1
46 Spacer ring 151F1502 1 1
47 Tacho valve housing 151F1802 1
a) 151F1498 1
48 O-ring 40 • 2 mm [1.57 • 0.08 in] 633B1378 1 1
49 Bearing housing 5.6 • 8.5 • 1 mm [0.22 • 0.33 • 0.04 in] 151F1499 1 1
50 Washer 684X2012 4 4
51 Screw M5; l = 15 mm [0.59 in] 681X1880 4 4
52 Tacho drive shaft 151F1500 1 1
53 Lockin ring UR 6 • 0.7 mm [0.24 • 0.03 in] DIN 6799 682L4922 2 2
54 Bearing 8 • 22 • 7 mm [0.31 • 0.87 • 0.28 in] 981X1020 1 1
NBR: Buna N, Perbunan (ISO 55 Shaft seal 633B3175 1 1
1629) FPM: Viton (ISO 1629) 56 Locking ring N 22 • 1 mm [0.87 • 0.04 in] DIN 472 682L4008 1 1
57 Name plate (Tacho) 151A0410 1 1
* Contained in spare parts
bag A, B, C or D A Set of seals NBR OMS, OMSW item 1, 3, 11, 12, 19, 28 and 29 151F0111 1 1
** OMSW wih brake nose and OMS (p.t.o.) item 1, 3, 11, 12, 19, 28 and 29 151F0117 1 1
drain port. Do not have B Set of seals NBR OMS, OMSW, OMSS item 11, 17, 19, 28 and 29 151F0103 1 1
check valve C Set of seals FPM OMS, OMSW, OMSS item 1, 3, 28 and 29 151F0109 1 1
a) see comments page 3 D Set of seals NBR OMSS item 11 and 17 151F1033 1 1
11007891 • Rev AD • Sep 2010 9

Special Tools
Special Tools A B
C D
E F
G A. Main holding tool SJ 151-9000-1

B: Holding tool for OMSS SJ 151F9000-1
C : Holding tool for OMSW SJ 151B9000-1
D: Mandrel for fitting shaft seal SJ 151F9000-7
E.: Mandrel for fitting PTO shaft seal SJ 151F9000-8
F : Holding tool for OMSW with brake nose SJ
151F9000-10
G: Holding tool for OMS SAE B - flange SJ
151F9000-11
Service tool drawing can be ordered from Sauer-Danfoss
10 11007891 • Rev AD • Sep 2010

Dismantling
Dismantling Item Part to remove Comments

4 Parallel key Cylindrical or tapered shafts
11* Conical seal ring
13, 14 Drain plug and washer
33 Seal plugs (2off ) Place the motor in holding tool.
38 Plugs (2 off ) Series 2 only Use I 5 mm Allan head spanner
37 Washer (2 off ) Series 2 only
36 Springs (2 off ) Series 2 only
Tilt motor, springs and balls come out.
35 Ball (2 off ) Series 2 only
34 Screw (4 off ) Use 17 mm socket spanner.
32 Valve housing Lift off carefully as a unit, holding your fingers under
the channel plate (Item no. 23).
23 Channel plate
19 O-ring Series 3 (2 off ), Series 2 (1off )
24 Stop ring Only on OMSS 200, 250, 400 and 500
25 Disc valve
30 Spacer
26 Balance plate Fill in oil into the spacer hole and use the ø14.25 mm
[0.56 in] mandrel as a piston to press up the balance
plate
27 Guide pin
28 O-ring
29 O-ring
31 Spring washer
22 Valve drive
21 Guide pin Series 2 only
20 Gearwheel set Hold fingers under the gearwheel set to prevent the
parts from dropping out
19 O-ring
18 Cardan shaft
15 Intermediate plate
11 Conical seal ring Not on OMSS, is already removed
12 O-ring
5, 6, Shaft incl. bearings Turn the bearing housing. Press out the shaft/bearing
7, 10**) assembly using a hydraulic press (pressing Force max.
2500 N [550 lbf ])
Shaft/bearing assembly should not be dismantled.
1**) Dust seal ring Item no. 1 and 3 to be knocked out by means of the
3 **) Shaft seal special mandrel (“D” on page 9)
* OMSS only
**) OMSS except
11007891 • Rev AD • Sep 2010 11

Dismantling
Tacho Connection Item Part to remove Comments

51 Screw (4 off )
44 Tacho connection Remove from tacho valve housing
48 O-ring
46 Spacer ring
56 Retaining ring Loosen tacho shaft package (by tapping lightly at the
end of the shaft) and extract the package from
tacho housing.
55 Shaft seal
53 Retaining ring (2 off )
54 Bearing
After dismantling, clean all parts in low aromatic kerosene.

Examine the parts and exchange them if necessary.
Immidiately before assembly, lubricate each part with hydraulic oil and grease rubber
parts with vaseline.
12 11007891 • Rev AD • Sep 2010

Assembling
Assembling Item Part to assemble Comments

3 *) Shaft seal Knock into position in the bearing housing, using the
assembly mandrel. Grease lip with vaseline.
1 *) Dust seal ring Use assembly mandrel and plastic hammer. Grease lip
with vaseline.
5, 6, 7, Shaft incl. bearings Use the hydraulic press. (max. 2500 N [550 lbf ])
10 *)
Always press on the bearing outer ring.
15, 12, 11 Intermediate plate, O-ring, conical seal Screw the guide bolts into the bearing housing.
ring Fit the O-ring into the bearing housing. Fit the conical
seal ring (biggest diameter facing the intermediate
plate) int the recess in the intermediate plate. Place
the intermediate plate in position on the bearing
housing with the conical seal ring downwards.
18 Cardan shaft Guide the cardan shaft down into the output shaft so
that the splines engage.
19 O-ring Grease with vaseline.
20, 21 Gearwheel set Hold fingers under the gearwheel set to prevent parts
falling out. Carefully lay the gearwheel set on the
intermediate plate so that the O-ring groove (OMS
series 3) or guide pin hole (OMS series 2) is upwards.
The through-hole (6 mm [0.24 in]) must line up with
the hole in the intermediate plate. Fit the guide pin
m (OMS series 2 only) in the gear rim. Mark the wheel
of the gearwheel set at the point where the bottom
of an internal tooth is opposite the bottom of an
external tooth (see drawing).
22 Valve drive Mark the tip of a spline tooth on the end of the valve
drive with the widest splines. Line up mark on rotor
and valve drive. The end with the widest splines must
point upwards.
Applies to motors with tacho connection:

Pin on valve drive must point upwards.
19 O-ring OMS series 3: 2 off Grease with vaseline. Mount in the gearwheel
OMS series 2: 1 off (only OMS serie 3) and channel plate groove.
11007891 • Rev AD • Sep 2010 13

Assembling
Assembling Item Part to assemble Comments

23 Channel plate (OMS series 3) Fit the channel plate so that the O-ring groove is
upwards and the check valve holes line up with the
through-hole in the gearwheel set.
Channel plate (OMS series 2) Fit the channel plate so that the guide pin engages
with the hole in the channel plate.
25 Disc valve Align mark on valve drive with a hole in the outer rim.
(A on drawing).
Turn disc valve counter clockwise until splines in the
two parts engage.
31 Spring washer Place into valve housing
28, 29 O-ring Fit the two O-rings (greased with vaseline) in the
balance plate grooves.
27 Guide pin Mount in valve housing
26 Balance plate Mount in valve housing
30 Spacer Grease with vaseline to prevent the spacer from
dropping out
32 Valve housing Mount unit on the rest of the motor. Ports should face
in the same direction as the drain port.
34 Screw (4 off ) Lubricate threads and cross tighten screws to 75 -
80 N.m [660 - 705 lbf.in].
36 Spring (2 off ) Series 2 only
37 Washer (2 off ) Series 2 only
38 Plug (2 off ) Series 2 only Tighten to 10 - 15 N.m [90 - 130 lbf.in]
4 Parallel key Secure with plastic ring or tape
13 Drain plug and washer Fill motor with oil before plugging. Tighten to 30
- 60 N.m [270 - 530 lbf.in].
11*) Conical seal ring Grease with vaseline to keep in place
33 Seal plug (2 off )
*) OMSS only
Assembling of Tacho The tacho connection must be reassembled in reverse order in relation to the procedure
Connection described under “disassembling the tache connection”.
4 screws (pos. 51) to be tightened to 4 - 6 N.m [35.5 - 53 lbf.in].
14 11007891 • Rev AD • Sep 2010

Notes
Notes
11007891 • Rev AD • Sep 2010 15

Products we oﬀer: Sauer-Danfoss is a global manufacturer and supplier of high-
quality hydraulic and electronic components. We specialize in
• Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
• Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
• Displays range of off-highway vehicles.
• Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
• Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
• PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
• Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
• Sensors
comprehensive global service for all of our components.
• Steering
• Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.
Local address:
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618
Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.hydro-gear.com Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, Yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Sauer-Danfoss-Daikin Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com
11007891 • Rev AD • Sep 2010

www.sauer-danfoss.com

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OMS Series 2

Service and Parts

Revision History Table of Revisions

Contents Special versions....................................................................................................................................................................3

© 2010 Sauer-Danfoss. All rights reserved.

2 11007891 • Rev AD • Sep 2010

Comments a) Only OMS series 2:

OMSW Series 3 with

11007891 • Rev AD • Sep 2010 3

Exploded View OMS

Item 13, with item 14: 30 - 60 N.m [ 270 - 530 lbf.in]

4 11007891 • Rev AD • Sep 2010

Exploded View OMS

Item 13, with item 14: 30 - 60 N.m [ 270 - 530 lbf.in]

11007891 • Rev AD • Sep 2010 5

Exploded View OMS

Item 34: 75 - 80 N.m [660 - 705 lbf.in]

6 11007891 • Rev AD • Sep 2010

Spare Parts List Item Spare parts Number per motor

11007891 • Rev AD • Sep 2010 7

Spare Parts List Item Spare parts Number per motor

8 11007891 • Rev AD • Sep 2010

Item Spare parts Number per motor

11007891 • Rev AD • Sep 2010 9

G A. Main holding tool SJ 151-9000-1

Service tool drawing can be ordered from Sauer-Danfoss

10 11007891 • Rev AD • Sep 2010

Dismantling Item Part to remove Comments

11007891 • Rev AD • Sep 2010 11

Tacho Connection Item Part to remove Comments

After dismantling, clean all parts in low aromatic kerosene.

12 11007891 • Rev AD • Sep 2010

Assembling Item Part to assemble Comments

Applies to motors with tacho connection:

11007891 • Rev AD • Sep 2010 13

Assembling Item Part to assemble Comments

14 11007891 • Rev AD • Sep 2010

11007891 • Rev AD • Sep 2010 15

Members of the Sauer-Danfoss Group:

Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

11007891 • Rev AD • Sep 2010

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